Mold.



W. M. PAGE.

MOLD.

APPLICATION FILED FEB. 8, I911.

2 SHEETS-SHEET 1.

Patented Apr. 6

W. M. PAGE.

MOLD.

AEPLICATJQN FILED FEB. 8, 19|| awn Gimuewtcw Specification of Letters latent.

Patented Apr. 6, il ilfi.

a nea... filed February a, 1911. Serial no. 607,338.

To all whom it may concern Be it known that 1, WILLIAM MARSHALL PAGE, a citizen of the United States, residing at Ridley Park, in the county of Delaware and State of Pennsylvania, have invented certain new and useful Improvements in Molds, of which the following is a specification.

This invention relates to molds; and it comprises a mold particularly adapted for producing clad metals, such as copper clad steel, and for other coating work, such mold comprising a casing, means for centering or otherwise locating an object to be coated therein and receiving means for molten coating metal located near the top of said casing and communicating with the chamber therein through one or more comparatively narrow orifices; all as more fully hereinafter described and as claimed.

In modern methods of coating steel with copper where the copper and steel are to be united with a Weld-like union, it is now customary in the art to give the steel a preliminary thin or film coat of firmly attached or welded-on copper or copper-iron alloy and thereafter .to attach to such coat a substantial body of copper or like metal to produce a compound article which may be rolled and drawn down to form finished articles. A steel billet may, for example, (see Patent 853,716) be dipped into superheated or supermolten copper and withdrawn into a non-oxidizing atmosphere carrying a film coating of the desired type. The copper of the dipping bath of course soon becomes contaminated with dissolved iron and as iron in the coating of clad metal is undesirable for many purposes, such as conductor wire, it is usual to restrict the amount of copper applied by the dipping operation to the clinging-on coat retained by the dipped billet in film coating on withdrawal from the dipping bath, a further and substantial coating of the copper being afterward applied by contacting the film coating with molten copper; this molten copper for clad metal goods intended for electrical conductors being of high purity and substantially free of iron. In this second operation of attachin the main body of pure copper many di culties occur. The filmcoating must be kept from contact with air, since otherwise the copper would oxidize and give a non-metallic surface and the molten copper cast against it .must not carry air into the mold. This molten copper, further, must not melt or wash the film unduly since it would thereby become contaminated with iron though it must of course come into direct contact with the coating while still in a molten state to form the fused and permanent union thatis desired. So while the 7 dipped bodily into a second bath of copper or like metal possessing the properties desired for the bod of the main coating. The molten copper 0 this second bath is allowed to flow into the casing through restricted orifices near its top, these orifices being so small as to provide vonly a limited flow from beneath the surface of the bath of molten copper, thereby precluding entrance of air,

floating copper oxid, covering flux, etc.

The flow orifices are kept sealed until wanted by a strip of asbestos.

Forming the main body of the coating by bodily plunging the mold beneath the surface of molten copper in the way described, while working well so far as making the desired type of clad metal with a substantial coating body of pure metal is concerned, is nevertheless inconvenient and .expensive as requiring much manipulation and the use of comparatively large bodies of molten pure copper. The size of the billetis of course limited by the size of the crucible or other apparatus containing the molten copper. large billets very large crucibles must be used.

In the present invention 1 have devised .a type of mold allowing me .to obtain the main .coating'with as great certainty and of as high quality as by the dip-coating process described but with more convenience and economy. To thisend I provide a mold which may be, and advantageously is, see-- tional, having means for holding a billet of core ,metal Within the mold cavity and havlng at or near its .top one or more comparatively small openings for molten metal, these openings commumcating with a receiver for while a comparatively large amount of molten metal may be cast into the receiver at onetime the feed of molten metal into the mold cavity therefrom shall be comparatively small and regular. With this arrangement the molten metal-in the receiver may, and does, cover the inflow orifices during the greater period of the coating operation proper and thereby precludes the carrying of air, oxid, dross, flux, etc., into the mold casing.

Advantageously the mold is made of two or more flan ed sections so that after the completion 0 the cast it may be easily removed from the coated billet. Thejflanges may be slotted to receive bolts. When not sectional the coated billet must ordinarily be removed by a ram which is inconvenient and laborious. It is best also provided with a removable base and with handling means so that it maybe used as an open-bottomed protective casing during the dip filming operation described, the base being removed for this purpose and the billet thrust downward ol lt of the mold and into super-molten copper in the usual way. The mold should also be provided with a top cover, and this may very advantageously be in the nature of a chuck having means'for gripping the mold body. This construction of the mold obviates the necessity for a separate gas cas-.

ing and the trouble of and danger intransporting the filmed billet between such a casing and the mold.

Since the mold is not intended later to enter the copper bath, with the present apparatus there is no necessary correlation between the size of the billet to be coated and the size of the bath of coating metal. The coating metal may be derived from comparatively small crucibles, from tilting furnaces or from any other desired apparatus. The mold chamber may of course be of any contour or size and may have billetlocating means adapted to center a billet or hold it at one side; this depending on whether a billet coated on all-sides or only on certain sides is desired.

' The mold may be made of any suitable strong and resistant material. An iron or steel mold covered with a graphite, carbon or clay wash is suitable for making copper clad steel billets.

In the accompanying drawings I have shown, more or less diagrammatically, one

of the many embodiments of which the pres ent invention iscapable.

In this showing Figure 1 is an elevation. of the assembled mold. certain 'parts being in section: Fig. 2 is a plan, partly in section, of the mold with the. chuck or cover removed; Fig.3 is a plan of the chuck; Fig.

. spider; Fig. 7 shows a false bottom for the mold; and Fig. 8 is a view on a smaller scale of one of the mold sections.

Referring to the drawings, 1 is the mold body or casing as a'whole, seated upon a removable base 2 and surmounted by a cap or chuck 3 serving as a cover. The mold body is divided into sections 4 and 5,-these sections being held together by bolts 6 provided with adjusting nuts 6 and fitting loosely in slots 7 formed in flanges 8 of the mold sections, the slots of abutting flanges being arranged to register in pairs. To facilitate a tight joint between the mold sections, strips 9 of asbestos or other refractory packing material may be inserted between the flanges of the sections. In the upper portion of the mold body are provided casting orifices 10 which are best rather small. Means for receiving molten metal such as hoppers or receivers 11 are mounted upon the sides of the mold body and are so positioned that the casting orifices before mentioned open into the hoppers at or near the bottoms of the latter. Where the mold body is unitary instead of sectional, these separate hoppers may be replaced if desired by a hopper or gutter extending continuously around the mold body. It is well to place shields or aprons 12 of fire clay or other refractory material above the casting orifices to prevent undue cutting away of the metal of the mold by the metal being poured and avoid damage to the mold and contamination of the metal being cast. Vents 10*, which may be located at any convenient point and which may be closed except during the casting operation by removable closures 10 of asbestos or other suitable material, permit escape of gases displaced from the mold in casting. The lower edge of the mold body may be flanged as at 13 and slightly beveled to fit into a corresponding annular recess 14 in the removable base. The base is also best provided with peripheral beveled guide memhere 15 which assist in obtaining rapid and accurate registry of the flange with the recess. If desired, the false bottom shown in Fig. 7 may be placed over the true base before assembling the latter with the mold body, for the purpose of protecting the base against the action of the metal being cast; but this false bottom may be dispensed with.

The upper part of the mold body may be somewhat constricted to form what may be termed a throat 16 provided with holes and sockets 17 for a purpose hereinafter exmenace plained. Upon this throat is designed to seat the chuck (3) before mentioned, the joint between the parts being as nearly gastight as is practicable, plate 18 being secured to the bottom of the chuck for this purpose. The body of the cover or chuck comprises a heavy framework 19 through which pass bolts 20 provided at their threaded upper ends with capped nuts 21 and at their lower ends with yokes 22, between the arms of which swinging clamps or jaws 23 are pivotally secured by means of bolts or shafts 24 passing through the yoke arms and the jaws. The free ends of the jaws are bored to admit pins or studs 25 which register with and enter the holes or sockets (17) in the throat of the mold body. Within the chuck is chamber 26 having a gas inlet 27 on one side, and provided with centrally located and alined openings 28 and 29 in thetop and bottom respectively, these openings being best lined with suitable bushings 30, 30. Anchored in bosses 32 on the framework of the chuck are rings or other suitable means 33 to which may be attached hooks or chains of a hoisting device. Arranged outside of the bottom opening 29 are a number of smaller bores 31 which serve to admit gas from the chuck chamber to the mold.

In Figs. 5 and 6 is shown a device which may be usefully employed in centering a billet in the new mold. This device comprises a spider having a hub 34: and arms 35, the latter being of suiiicient length to extend slightly beyond the corners of the billet to be clad. The hub is provided with a threaded bore within which is best located a threaded plug 36 whose function will appear hereafter.

The method of using my new mold will be best understood from a brief description of the series of steps involved in producing' a copper clad steel billet. The steel billet 37 having been pickled, sandblasted, or otherwise treated to insure its surface being clean, one threaded end of a rod 38 is screwed into a tapped hole in the end of the billet, the other threaded end of the rod having previously been screwed into the threaded bore of the spider hub (34) and locked therein by abutment against the plug (36). The mold chuck, detached from the remainder of the mold, is suspended from a hoist, and a porter bar 39, also attached to the hoist in such a way as to allow relative motion between the porter bar and the chuck, is passed through the alined orifices (28) and (29) in the chuck. The lower end of the porter bar is threaded and fits the threaded bore of the spider hub into which the bar is screwed until it abuts and is locked by the plug (36). In practice it is found advisable to interpose a shield of refractory material, such as a block of graphite 40, between the centering spider and the top of the billet in order to protect the latter and the rod (38) from the cutting action of the molten copper in the casting operation. This shield may be large enough to cover the entire top of the billet.

The chuck and billet after being assembled are quickly carried by the hoist to the open mold and the billet lowered into the mold. This billet has been previously treated to give it a surface adapted for coating. The chuck is also lowered until it seats on the upper edge of the mold throat, and the pivoted jaws are swung into engagement with the sockets in the throat, thus firmly locking together the chuck and mold body or casing. Gas supply means at may then be immediately attached to the gas inlet in the chuck and inert or reducing gas, such as nitrogen or producer gas, passed into the mold to prevent oxidation of the clean surface of the billet. The interior of the mold and all parts likely to come in contact with the molten copper are carefully swabbed with a refractory wash before the insertion of the billet. With gas continuing to pass freely into the mold, the chuck and mold casing, together with the inclosed billet, are lifted and positioned over a vessel containing copper heated to a temperature considerably above its melting point, a. 6., copper in a supermolten or uniting condition. In this operation the bottom of the casing is open, the removable base not being in place. Into this copper the billet is lowered out of the mold casing to receive the preliminary or film coat of weld-united copper. The duration of this dip is somewhat variable but is always relatively brief. The billet is then withdrawn from the bath of supermolten copper carrying its alloy film into the mold casing into which the passage of gas is continued in order to protect the film from oxidation. The billet together with the chuck and casing is then set upon the base. Molten copper, which may be, and advantageously is, at a lower temperature than was used for the fihning dip and which has been treated if necessary to secure the requisite degree of purity, is then poured into the hoppers or receivers on the mold body, flowing therefrom into the mold through the relatively small openings near the bottom of the hoppers. Casting may be done conveniently from rather small crucibles or ladles. Ordinarily a rather small amount of molten copper is first poured into the hoppers and the main body of molten copper added after a short pause. In this way the copper first added, flowing to the mold bottom, solidifies in and seals any small cracks or other openings which there may be between the bottom and the mold casing. Furthermore this small amount of copper first added may be splashed down over the billet and may serve to Wash from in; I

its surface any minute quantities of oxid, etc., which may have formed thereon when the billet was withdrawn from the filming bath into the bottomless casing. The casting operation should be accompanied by a .vigorous flow of non-oxidizing gas into the mold to oppose inward passage of air. The casting orifices being relatively small as compared to the hoppers and being located near the bottom of the latter, they may be covered throughout the casting process by a substantial depth of molten copper, the entrance into the mold of an oxidizing atmosphere or of slag and oxids floating on the molten copper being thus effectually precluded. The depth to which the casting holes are covered is regulated of course by the rate at which the molten metal is poured into the hopper, but in casting copper around a filmed billet, the depth of metal in the hopper should be suflicient to insure nonentry of air, etc., into the mold interior through the casting holes. After the casting operation, the mold and contents are allowed to stand for a few moments until porter bar and centering spider. The reassembling of the mold parts is of course very simple and too obvious to requlre explanation.

may be used successively with any number of mold bodies and covers. The assembled mold body and cover serve as a. hood or shielding means .for the billet during the filming step and during the other necessary incidental handling of the billet; andwhile the mold is so employed, the bottom is, or may be, left open.

What I' claim is 1. A separable casting mold, comprising a mold body having a mold cavity therewithin, a casting orifice in the upper partof said body communicating with said cavity, metal receiving means mounted on said body portion in casting relation to said 'orifice,

a separable base adapted to register with said mold body and cover said cavity, a cover registering with said mold body and protecting said cavity against access of 0 air, and means on said cover adapted to grip said body.

2. A separable casting mold, comprising a mold body having flanged sections, a casting orifice of relatively small dimensions near the top of said body, a hopper mounted Since the mold base is required only during the final casting operation, one such baseon said body and in open communication with said casting orifice, a separable base, a cover fitting closely on said mold body and gripping means connecting said body and cover.

3. A billet coating mold comprising a mold body having a mold cavity and seating upon a separable base, means near the top of said mold body for .receiving molten metal, a casting orifice of small size through said mold body and connecting said receiving means with the interior of the mold, a chuck adapted to seat upon and cover said mold body and protect the cavity against access of air, and means for attaching said chuck to said mold body.

4. A sectional mold for coating billets, comprising a' sectional mold body seating upon a separable base, a metal receiving hopper mounted on the upper portion of said body, casting orifices in said body opening through the mold body into said hopper near the base thereof, a removable cover seating upon and gripping said mold body.

5. A sectional mold for coating billets, comprising a sectional mold body having flanged sections and seating upon a separable'base, hopper-like molten metal receiving means mounted on said mold body, casting openings in said mold body connecting said receiving means with the interior of the mold, a cover for said'mold body, gripping means connecting theremovable top and body and gas-introducing means connected to the mold. I

6. In a billet coating mold, a mold body adapted to receive therein a billet tobe coated, a separable base for the mold body, a cover for the mold orifice to permit extension-of a billet supporting member therethrough and swingable' gripping members connecting the cover and the body.

7 In a billet coating. mold, a mold body adapted to receive therein a billet to, be coated, a separable base for the mold body, a cover vfor the mold orifice to permit eX-' tension of a billet supporting member therethrough, swingable gripping members connecting the cover and the body, and jaws pivoted in said cover and adapted to grip said body.

8. In abillet coating mold, a mold body adapted to receive therein a billet to be coated, said body being recessed, a separable base for the mold body, a cover for the mold orificed to permit extension of a billet supporting member therethrough, swingable gripping members connecting the cover and the body, and jaws pivoted in said cover and adapted to engage the recess'es of said mold body.

9. A separable billet coating mold, comprising body sections, flanges on said sections, adjustable means engaging said flanges and securing said sections together, a separable mold base, a removable mold cover orificed to permit passage of billet supporting means therethrough, and clamps secured to said cover and adapted to engage said body sections.

10. A separable billet coating mold adapted to receive therein a billet to be coated, comprising body sections, flanges on said sections, adjustable means engaging said flanges and securing said sections together, casting hoppers mounted near the upper ends of said body sections and having casting communications with the mold interior, a separable mold base, a removable mold cover orificed to permit extension of billet supporting means therethrough, and clamps secured to said cover and adapted to engage said body sections.

11. A billet-coating mold, comprising a mold body having a constricted upper portion or throat, sockets in said throat, a cover adapted to seat on said mold body, and members pivoted on said coverand adapted to engage said sockets.

12. In a separable mold, a mold cover comprising a body portion adapted to register With a mold top, and clamps pivotally mounted on said body portion, said body portion having a centrally disposed aperture extending therethrough and adapted to permit passage of billet hoisting means through said cover.

13. In a coating mold adapted to receive a billet to be coated, a mold body having an open base, a separable bottom adapted to engage and seat thereon, a removable cover adapted for gripping engagement and disengagement with said body, said cover being orificed to permit extension of billet supporting means therethrough and side-pour means located near the top of said mold, said means comprising a receiver for molten metal communicating with the mold cavity through restricted orifices.

14. In a coating mold adapted to receive a billet to be coated, a mold body having an open base, a separable bottom adapted to engage and seat thereon, a removable cover adapted for gripping engagement and disengagement with said body, said cover being orificed to permit extension of billet supporting means therethrough, means for supplying inert gas to said mold and side-pour supporting means means located near the top of said mold, said means comprising a receiver for molten metal communicating with the mold cavity through restricted orifices.

15. In a billet coating mold, a separable body having-flange-unions, a separable base engaging the bottom of said body, sidepour means located near the top of the body and comprising a receiver for molten metal communicating with the mold through one or more narrow orifices a separable cover for the top of the mold having an orifice for the extension of billet supporting means therethrough, and gripping means engaging body and cover.

16, In a billet coating mold, a mold body having recesses, a separable cover orificed to allow extension of billet-supporting means therethrough, means for attaching hoisting means to said cover, movable connecting means on said cover adapted to engage said recesses, and a separable baseengaging said body.

17, In a billet coating mold, a two-part mold body having flanged unions, a separable base, a metal receiving hopper near the top of the body and communicatmg with the cavity thereof through a small orlfice, a cover for the top of the mold having a central orifice to allow extension of billet-supporting and centering means therethrough, and swingable locking bolts connectmg the cover and the body. o

18. A mold for coating billets comprising a mold body, a separable base plate arranged to close the lower end of the mold body, a removable cover arranged to substant ally seal the upper end of the mold body, billetarranged to extend through an orifice in said mold cover for mtroducing a billetinto or removing a billet from either end of the mold body, means for introducing a protective gas into said mold body, and lateralhopper-like means on the mold body for receiving molten metal, said receiving means being in casting communication with the mold interior.

In testimonywhereof, I aflix my signature in the presence of witnesses.

P. M. Wnrs, J. B. BRUNDAGE.

L PAGE. 

